Mitsubishi Lancer Evolution 6 1999-2001 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Model Generation: CP9A Codes Chassis Code: CP9A 👋 Introduction Market Position Category: Performance Rally Homologation Special Target Audience: Enthusiasts, owners, and professional mechanics working on the Lancer Evolution VI. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale. Key Features Unique Selling Points: Legendary rally pedigree, advanced AYC system, robust 4G63 engine, high-performance braking and suspension. 📋 Manual Details Coverage Areas Covered Years: 1999, 2000, 2001 Specific Models Covered: Lancer Evolution VI GSR, Lancer Evolution VI RS (and potentially special editions like Tommi Makinen Edition) Page Count Estimated Page Count: Highly variable, typically 1000+ pages for comprehensive factory service manuals. Manual Type Type: Service and Repair Manual Language Language: English (typical for international markets, original may be Japanese) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing belt/chain, valve train. Engine Performance: Fuel injection system (MPI), ignition system, turbocharging system (TD05HR-16G/15G), intercooling, emission control systems. Transmission: 5-speed manual transmission (RS and GSR), transfer case, differentials (front, center, rear - AYC system). Drivetrain: Driveshafts, CV joints, wheel bearings, propeller shaft. Suspension: Front suspension (MacPherson struts), rear suspension (Multi-link), shock absorbers, springs, control arms, stabilizer bars, Active Yaw Control (AYC) system components. Brakes: Front disc brakes (Brembo 4-piston calipers), rear disc brakes (Brembo 2-piston calipers), ABS system, brake hydraulics, parking brake. Steering: Power steering system, steering gear, steering column, tie rods. Electrical System: Battery, alternator, starter motor, lighting system, wipers, horn, power windows, central locking. Engine Control System: ECU (Engine Control Unit), sensors (MAP, TPS, knock, O2, camshaft/crankshaft position), actuators (idle control valve, injectors). Body And Chassis: Body construction, exterior panels, interior trim, doors, hood, trunk, bumpers, chassis components. HVAC: Heating, Ventilation, and Air Conditioning system, components, and service. Safety Systems: Airbag system, seatbelts, ABS. Procedures Included Routine Maintenance: Oil and filter changes, coolant checks and flushes, spark plug replacement, air filter replacement, brake fluid checks, tire rotation. Troubleshooting: Diagnostic procedures for common and uncommon issues, diagnostic trouble codes (DTCs), fault finding guides. Engine Repair: Engine overhaul, piston ring replacement, bearing replacement, head gasket replacement, timing belt service, turbocharger replacement. Transmission Repair: Clutch replacement, transmission fluid change, differential service, AYC system maintenance and calibration. Suspension And Steering Repair: Strut replacement, control arm replacement, ball joint replacement, power steering pump and rack service. Brake System Repair: Brake pad and rotor replacement, caliper overhaul, ABS bleeding, hydraulic line replacement. Electrical Diagnosis And Repair: Wiring diagrams, component testing, starter/alternator testing, sensor diagnostics. Body And Interior Repair: Panel replacement, trim removal and installation, door and window mechanism repair. HVAC Service: Refrigerant handling, component replacement (compressor, condenser, evaporator). Torque Specifications: Detailed torque values for all critical fasteners across all systems. Technical Depth Depth: Comprehensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced diagnostic procedures and specialized system (AYC) explanations. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content within PDF for efficient information retrieval. Print Quality Quality: High-resolution scans, suitable for printing specific sections or the entire manual. Binding Type Type: N/A (Digital PDF download) Paper Type Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (DOHC, 16-valve, turbocharged inline-4) Displacement: 2.0 Liters (1997 cc) Performance Horsepower: 276 hp @ 6500 rpm (JDM 'Gentleman's Agreement' figure, actual often higher) Torque: 275 lb-ft (373 Nm) @ 3000 rpm Redline: 7500 rpm Boost Pressure: Approx. 1.3 bar (18.85 psi) peak (variable with intercooler and tune) Fuel System Injection Type: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (98 RON recommended) Fuel Injectors: High-flow injectors (e.g., Bosch 440cc or equivalent for performance applications) Engine Internals Pistons: Forged aluminum pistons Connecting Rods: Forged steel connecting rods Cooling System Radiator Capacity: Approx. 7.0 Liters Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (or equivalent blue ethylene glycol coolant) Lubrication System Oil Capacity: Approx. 4.5 Liters (with filter) Recommended Oil Viscosity: 10W-40 or 5W-40 (synthetic recommended) Turbocharger Model: Mitsubishi Heavy Industries TD05HR-16G (larger variant for Evo 6) 🔧 Transmission Standard Type: 5-Speed Manual Transmission (Type R) Gear Ratios: Specific ratios vary by model (e.g., RS vs. GSR), but designed for performance. Differential Type: Front: Helical LSD; Center: Active Center Differential (ACD) with electronic control; Rear: Helical LSD with AYC (Active Yaw Control) Transmission Fluid Capacity: Approx. 2.4 Liters (Manual Transmission) Transmission Fluid Type: Mitsubishi DiaQueen GL-4 SAE 75W-85 or equivalent (check manual for specific AYC fluid) Optional Type: N/A (Only manual transmission offered for Evolution models) Features Active Yaw Control: AYC system electronically controls torque split to rear wheels for enhanced cornering stability. 📐 Dimensions Exterior Length: 4350 mm (171.3 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2600 mm (102.4 in) Track Width...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VI (Evo 6)

Model Generation:

Codes

Chassis Code:

👋 Introduction

Market Position

Category:

Performance Rally Homologation Special

Target Audience:

Enthusiasts, owners, and professional mechanics working on the Lancer Evolution VI.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale.

Key Features

Unique Selling Points:

Legendary rally pedigree, advanced AYC system, robust 4G63 engine, high-performance braking and suspension.

📋 Manual Details

Coverage Areas

Covered Years:

1999, 2000, 2001

Specific Models Covered:

Lancer Evolution VI GSR, Lancer Evolution VI RS (and potentially special editions like Tommi Makinen Edition)

Page Count

Estimated Page Count:

Highly variable, typically 1000+ pages for comprehensive factory service manuals.

Manual Type

Type:

Service and Repair Manual

Language

Language:

English (typical for international markets, original may be Japanese)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing belt/chain, valve train.

Engine Performance:

Fuel injection system (MPI), ignition system, turbocharging system (TD05HR-16G/15G), intercooling, emission control systems.

Transmission:

5-speed manual transmission (RS and GSR), transfer case, differentials (front, center, rear - AYC system).

Drivetrain:

Driveshafts, CV joints, wheel bearings, propeller shaft.

Suspension:

Front suspension (MacPherson struts), rear suspension (Multi-link), shock absorbers, springs, control arms, stabilizer bars, Active Yaw Control (AYC) system components.

Brakes:

Front disc brakes (Brembo 4-piston calipers), rear disc brakes (Brembo 2-piston calipers), ABS system, brake hydraulics, parking brake.

Steering:

Power steering system, steering gear, steering column, tie rods.

Electrical System:

Battery, alternator, starter motor, lighting system, wipers, horn, power windows, central locking.

Engine Control System:

ECU (Engine Control Unit), sensors (MAP, TPS, knock, O2, camshaft/crankshaft position), actuators (idle control valve, injectors).

Body And Chassis:

Body construction, exterior panels, interior trim, doors, hood, trunk, bumpers, chassis components.

HVAC:

Heating, Ventilation, and Air Conditioning system, components, and service.

Safety Systems:

Airbag system, seatbelts, ABS.

Procedures Included

Routine Maintenance:

Oil and filter changes, coolant checks and flushes, spark plug replacement, air filter replacement, brake fluid checks, tire rotation.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, diagnostic trouble codes (DTCs), fault finding guides.

Engine Repair:

Engine overhaul, piston ring replacement, bearing replacement, head gasket replacement, timing belt service, turbocharger replacement.

Transmission Repair:

Clutch replacement, transmission fluid change, differential service, AYC system maintenance and calibration.

Suspension And Steering Repair:

Strut replacement, control arm replacement, ball joint replacement, power steering pump and rack service.

Brake System Repair:

Brake pad and rotor replacement, caliper overhaul, ABS bleeding, hydraulic line replacement.

Electrical Diagnosis And Repair:

Wiring diagrams, component testing, starter/alternator testing, sensor diagnostics.

Body And Interior Repair:

Panel replacement, trim removal and installation, door and window mechanism repair.

HVAC Service:

Refrigerant handling, component replacement (compressor, condenser, evaporator).

Torque Specifications:

Detailed torque values for all critical fasteners across all systems.

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced diagnostic procedures and specialized system (AYC) explanations.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content within PDF for efficient information retrieval.

Print Quality

Quality:

High-resolution scans, suitable for printing specific sections or the entire manual.

Binding Type

Type:

N/A (Digital PDF download)

Paper Type

Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63 (DOHC, 16-valve, turbocharged inline-4)

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower:

276 hp @ 6500 rpm (JDM 'Gentleman's Agreement' figure, actual often higher)

Torque:

275 lb-ft (373 Nm) @ 3000 rpm

Redline:

7500 rpm

Boost Pressure:

Approx. 1.3 bar (18.85 psi) peak (variable with intercooler and tune)

Fuel System

Injection Type:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (98 RON recommended)

Fuel Injectors:

High-flow injectors (e.g., Bosch 440cc or equivalent for performance applications)

Engine Internals

Pistons:

Forged aluminum pistons

Connecting Rods:

Forged steel connecting rods

Cooling System

Radiator Capacity:

Approx. 7.0 Liters

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent blue ethylene glycol coolant)

Lubrication System

Oil Capacity:

Approx. 4.5 Liters (with filter)

Recommended Oil Viscosity:

10W-40 or 5W-40 (synthetic recommended)

Turbocharger

Model:

Mitsubishi Heavy Industries TD05HR-16G (larger variant for Evo 6)

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (Type R)

Gear Ratios:

Specific ratios vary by model (e.g., RS vs. GSR), but designed for performance.

Differential Type:

Front: Helical LSD; Center: Active Center Differential (ACD) with electronic control; Rear: Helical LSD with AYC (Active Yaw Control)

Transmission Fluid Capacity:

Approx. 2.4 Liters (Manual Transmission)

Transmission Fluid Type:

Mitsubishi DiaQueen GL-4 SAE 75W-85 or equivalent (check manual for specific AYC fluid)

Optional

Type:

N/A (Only manual transmission offered for Evolution models)

Features

Active Yaw Control:

AYC system electronically controls torque split to rear wheels for enhanced cornering stability.

📐 Dimensions

Exterior

Length:

4350 mm (171.3 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2600 mm (102.4 in)

Track Width Front:

1515 mm (59.6 in)

Track Width Rear:

1510 mm (59.4 in)

Weights

Curb Weight:

Approx. 1270-1300 kg (2800-2866 lbs) depending on trim

Gross Vehicle Weight Rating:

Not commonly specified, but designed for performance driving.

Wheels Tires

Wheel Size:

17 x 7.5 inch (standard GSR), 17 x 7.0 inch (RS)

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Tire Size:

215/40ZR17 (standard), 205/50R16 (RS)

🛡️ Safety Features

Ratings

Crash Test Results:

No official NHTSA/Euro NCAP ratings available for this era of homologation specials, but built to robust rally standards.

Active Features

Anti-lock Braking System (ABS)

Active Yaw Control (AYC) for enhanced stability and traction.

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point seatbelts with pre-tensioners.

Chassis Construction:

Reinforced chassis structure with integrated roll cage elements (especially in RS models).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette/CD player with basic speaker system. Aftermarket upgrades are common.

Driver Assistance

Active Yaw Control:

AYC is the primary electronic driver assistance system, managing torque distribution for enhanced handling.

Connectivity

Original Features:

Limited by era; no built-in Bluetooth, USB, or smartphone integration. Manual covers electrical systems that support these potential upgrades.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (more frequent under hard driving).

Spark Plugs:

Approximately 40,000 - 60,000 km (25,000 - 37,000 miles) depending on plug type.

Timing Belt:

Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 6-7 years (critical replacement).

Transmission Fluid:

Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 2-3 years.

Coolant Flush:

Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 2-3 years.

Fluid Specifications

Engine Oil:

API SG/SH or ILSAC GF-2 specification, viscosity 10W-40 or 5W-40 (full synthetic recommended for performance).

Transmission Fluid:

Mitsubishi DiaQueen GL-4 SAE 75W-85 or equivalent.

Brake Fluid:

DOT 3 or DOT 4 (high-performance, low-moisture content fluid recommended).

Power Steering Fluid:

Dexron II or equivalent ATF.

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (blue) or equivalent 50/50 mix of ethylene glycol and distilled water.

Known Issues

Engine Wear:

Potential for piston ring wear or ring land failure if poorly maintained or consistently driven hard without proper warm-up/cool-down cycles. Rod bearing wear is also a concern under extreme use.

Ayc System:

AYC pump can fail over time due to wear or contamination. Sensors and solenoids can also be a source of issues.

Turbocharger:

Oil starvation or contamination can lead to turbo failure. Regular oil changes and proper cool-down are crucial.

Clutch:

Clutch wear is normal, but aggressive driving can accelerate it. Clutch release bearing can also fail.

Rust:

As with many cars of this era, rust can be an issue, particularly in the sills, wheel arches, and subframes, especially in areas with harsh winters.

📚 Vehicle History

Brand Heritage

Rally Success:

Mitsubishi has a storied history in the World Rally Championship (WRC), with the Lancer Evolution being a dominant force.

Model Evolution

Evo Lineage:

The Evo 6 builds upon the technological advancements of its predecessors, refining performance and handling.

Tommi Makinen Edition:

Special edition released to celebrate Tommi Mäkinen's WRC titles, featuring unique styling, suspension upgrades, and often a titanium-cored turbocharger.

Production

Production Years:

1999 - 2001

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Rally Prowess:

The Lancer Evolution line is synonymous with rally success, directly influencing its reputation and desirability.

Performance Credentials:

Consistently praised by automotive journalists for its sharp handling, powerful engine, and effective all-wheel-drive system.